System for forming strings of pocketed coil springs

Abstract

A string of pocketed coil springs is formed by inserting compressed springs between upper and lower plies of a folded, preferably thermally weldable fabric. The springs are maintained in a compressed configuration while a longitudinal seam joins the free edges of the thermally welded fabric together. Subsequently, the compressed springs are allowed to relax into an expanded configuration after which a transverse seam is formed in the fabric between the adjacent springs thereby encapsulating each spring within a fabric pocket. The string of pocketed coil springs is advantageously formed without the need for reorienting the springs after being inserted between the plies of the fabric and thereby avoiding the disadvantages and complications associated with turning or reorienting the pocketed coil spring.

Description

This is a continuation-in-part of U.S. patent application Ser. No. 09/293,221, filed Apr. 16, 1999 now abandoned and hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

This invention relates generally to spring assemblies for mattresses, cushions and the like, and, more particularly, to a method and system for making a string of connected individually pocketed coil springs for mattresses, cushions, spring units and the like.

Pocketed coil springs are often referred to as a Marshall construction in which each coil spring is encased within its own fabric sack or pocket. The sack or pocket is typically defined between two plies of a fabric strip connected together at intervals along transverse lines spaced along the strip. The two-ply fabric strip is generally formed by folding a strip of double width fabric upon itself along a longitudinal centerline, leaving the overlapped plies along the unjoined opposite edges of the strip to be connected to each other along a longitudinal seam to close the pockets defined between the transverse lines of connection after the springs are inserted between the plies.

A variety of techniques have evolved for the manufacture of pocketed springs, some contemplating the creation of the pockets within the fabric plies prior to insertion of the wire spring and others contemplating the insertion of compressed wire springs between the plies of the strip and the subsequent creation of the pockets by stitching or otherwise joining the two plies to each other along transverse lines between adjacent springs. Irrespective of the technique used, the fabric is closed around the spring after the insertion of the spring, usually by stitching or welding the two plies together along a line parallel to the free edges of the plies. Joining the plies together by stitching has largely been replaced in more recent times by the use of a heat sensitive fabric and ultrasonic welding techniques. Examples of known systems and techniques for manufacturing strings of pocketed coil spring are disclosed in U.S. Pat. Nos. 4,439,977; 4,234,983; and 5,613,287, each of which are incorporated herein by reference.

Specifically, in U.S. Pat. No. 4,439,977, a method and apparatus are disclosed for making coil springs enclosed within individual pockets in an elongate fabric strip comprised of two overlying plies capable of being thermally welded together. The fabric strip is fed along a guide path during which compressed springs are inserted between the plies with the axes of the springs substantially normal or perpendicular to the planes of the plies. Thereafter, the fabric plies are thermally welded together longitudinally and transversely while the spring remains compressed to form a string of pocketed coils. After thermal welding, the pocketed coils are passed through a turner assembly during which the springs are reoriented typically about 90°C within the fabric pockets to positions wherein the axes of the springs are transverse to the fabric strip.

One specific disadvantage of this method of manufacturing pocketed coil springs is that during the turning process, springs tend to become entangled or hooked together and do not achieve their proper positions. As such, additional and costly labor is required to reorient and disentangle the springs to place them into their desired configurations and orientations. Even if the springs do not become entangled or hooked, difficulties may still arise in correctly aligning them to their desired positions with the longitudinal axes of the springs being substantially parallel to one another and the transverse seams defining individual pockets.

Another common problem with this type of operation is that during the turning of the pocketed springs, whether or not the springs become hooked or entangled and the turning process is successful, the fabric surrounding the spring is often damaged, torn, punctured or the like. In one form, the springs are beaten by paddles as disclosed in U.S. Pat. No. 4,439,977 to effect the turning of the spring within the pocket. Obviously, the repeated beating on the pocket with the paddles may cause significant damage to the fabric material and prove to be unreliable to accurately position the spring within the fabric pocket. When this happens, the damaged pocket should be repaired or removed from the string thereby interrupting the process and requiring significant operator intervention and down time for the production of pocketed coil springs.

Therefore, a need exists for a method and system for forming strings of pocketed coil springs which overcomes the above described disadvantages of the prior art and does not require the turning of the springs within the pockets for alignment of the spring axes in a generally parallel and ordered arrangement nor operator intervention to unhook or disentangle the springs nor repair the damaged fabric surrounding the springs. Further, a need has always existed to provide commercially viable methods and systems for producing strings of pocketed coil springs which are cost and labor effective by requiring a minimal amount of labor intervention and associated resources.

SUMMARY OF THE INVENTION

The present invention overcomes the above described and other disadvantages in the prior art by providing an improved method and system for producing strings of pocketed coil springs which are effective in performance, yet cost effective in that it requires a minimum amount of materials and labor. The manner in which the springs are inserted into the fabric and the formation of the pocket according to this invention avoids the need for turning or repositioning the springs within the pockets while still providing an efficient and reliable manufacturing system and associated method for reliably producing consistently aligned springs within undamaged fabric pockets.

The present invention preferably begins with the insertion of a compressed coil spring between upper and lower plies of a folded thermally welded fabric. The present invention is a continuous production process such that the fabric is indexed or pulled past a spring insertion station so that the compressed springs are individually inserted between the plies of the folded fabric at spaced intervals as the fabric passes the spring insertion station. The springs are maintained in a compressed configuration between the plies of the fabric while a longitudinal seam is formed in the fabric to join the two plies together proximate free edges of the plies opposite from a longitudinal fold line of the fabric. Since the fabric is a thermally weldable material, preferably the longitudinal seam is formed by a cooperating thermal weld head and anvil combination. After the spring has advanced past the longitudinal weld station, it is allowed to relax and expand within the fabric into an upright position in which a longitudinal axis of the spring is generally perpendicular to the longitudinal seam of the fabric. Preferably, the relaxation and expansion of the springs within the fabric is controlled by a pair of rotating members on opposite sides of the springs according to various alternative embodiments of this invention. The rotating members in presently preferred embodiments may be a pair of oppositely rotating wheels with axes of rotation generally parallel to the longitudinal axes of the springs. The wheels include a plurality of arcuate-shaped recesses which combine to partially surround each spring during the expansion. Alternatively, the rotating members may include a pair of bands each passing over a pair of spaced rollers. The fabric and springs pass between the bands and a separation distance between the bands increases in a downstream direction to thereby control the expansion of the springs between the bands. In either embodiment, the springs are supported during their expansion into an upright position.

After the springs have expanded within the fabric, individual pockets are formed preferably by a transverse weld head sealing the fabric between each of the springs generally parallel to the spring axes. The transverse seams are formed in the fabric to complete the individual pockets for the individual springs. Finally, a pair of opposing and rotating transport wheels indexes or moves the string of pocketed springs forwardly thereby advancing the fabric and enclosed springs through the various stations as described.

Advantageously, the orientation of the springs remains generally unchanged throughout the pocketing process so that reorientation, turning or the like of the springs within the pockets is avoided. Moreover, the longitudinal seam formed in the fabric is positioned on a side face of the individual spring pockets in the resulting string of pocketed coil springs thereby avoiding the problem known in the art known as "false loft". False loft occurs when the longitudinally extending seams maintain the cover material at a certain distance away from the ends of the springs so that when the mattress is first purchased, this distance is fairly uniform. However, after the mattress or cushion has been in use for a period of time, the longitudinally extending seams or other excess fabric in the pocketed coil string may become crushed thus leaving areas or regions of depression. With continued use of the mattress or cushion, the entire support surface of the mattress or cushion will similarly be crushed and will appear substantially flat. A user may not realize the source of this phenomenon and consider it to be a defect in the mattress or cushion.

The problem of false loft is thereby avoided in the present invention by positioning the longitudinal seam of the string of springs on a side thereof while still avoiding the need to turn or reorient the individual springs within the pockets and the resulting damage to the fabric and other associated problems.

Another feature of this invention which also aids in the reduction of false loft and related problems is particularly useful for barrel shaped springs or other such springs which have a non-linear profile. With such springs, the transverse seam between adjacent springs in the string is shaped to conform to the profile of the springs and thereby produce a tighter, more conforming fabric pocket around the spring to avoid bunching or excess loose fabric around the spring.

BRIEF DESCRIPTION OF THE DRAWINGS

The objectives and features of the invention will become more readily apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 is a top plan view of a schematic representation of a system and associated method according to a first embodiment for producing a string of pocketed coil springs of this invention;

FIG. 2 is a side elevational view of the system and method of FIG. 1;

FIG. 3 is a view similar to FIG. 1 of a second presently preferred system and associated method according to this invention;

FIG. 4 is a side elevational view of the system and method of FIG. 3;

FIG. 5 is a perspective view of a string of pocketed coil springs produced according to this invention;

FIG. 6 is a cross-sectional view of an individual coil spring encased within a fabric pocket as taken along line 6--6 of FIG. 5;

FIG. 7 is a side elevational view of a string of pocketed coil springs produced according to an alternative embodiment of this invention; and

FIG. 8 is a partial perspective view of a weld head used to weld a transverse seam in the string of FIG. 7.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, a first presently preferred embodiment of a system 10 and associated method for forming a string 12 of pocketed coil springs 14 according to this invention is shown. Fabric 16, preferably thermally weldable as is well known in the art, is fed from a supply roll 18 around a roller 20 as shown in FIG. 1. Alternatively, the fabric 16 could be cotton or another suitable material. The fabric 16 is folded generally in half longitudinally about a longitudinal fold line 22 which coincides approximately with a longitudinal centerline of the fabric 16. The fabric 16 is folded about the longitudinal fold line 22 to produce a first, upper ply 24 and a second, lower ply 26 of fabric 16 each with a free edge 28 spaced from the longitudinal fold line 22. The folded fabric 16 passes upper and lower input rollers 30, 32 prior to entering a spring insertion station 34. The rollers 20, 30 and/or 32 may be rotationally driven.

The spring insertion station 34 includes a reciprocating insertion plunger 36 having a cup-shaped spring receiving leading end 38 to receive therein a compressed coil spring 14. The plunger 36 extends to insert the compressed spring 14 between the plies 24, 26 and retracts to receive another compressed spring 14 for subsequent insertion. The spring 14 is formed and compressed and loaded onto the spring insertion plunger 36 and the fabric 16 is folded according to one of any number of well known systems and methods for doing so. Alternatively, the spring insertion station 34 may comprise two U-shaped profiles which keep the spring 14 compressed and lead the springs 14 inside the folded fabric 16. In this method, the spring 14 is held with a horn (not shown) while the profiles return.

As the fabric 16 advances through the system 10, the springs 14 inserted between the plies 24, 26 are maintained in a compressed configuration between upper and lower support plates 40, 42 on the upper and lower faces, respectively, of the fabric 16 as particularly shown in FIGS. 1 and 2. Preferably, the support plates 40, 42 are centered between the free edges 28 and longitudinal fold line 22 of the fabric 16 and may include a wider region 44 proximate the spring insertion station 34 which tapers downwardly to a region of smaller separation 46 between the plates 40, 42 as the fabric 16 and springs 14 advance through subsequent portions of the system 10.

Additionally, a plurality of spaced alignment wheels 48 which are mounted for rotation proximate the longitudinal fold line 22 and free edges 28 of the fabric 16 control and direct the movement of the fabric 16 through the system 10. The alignment wheels preferably include a plurality of projections 50 which engage the fabric 16 to maintain the movement of the fabric 16 in an aligned orientation with respect to the various stations and components of the system 10.

A longitudinal seam forming station 52 is located downstream from the spring insertion station 34 proximate the free edges 28 of the fabric 16, as shown in FIGS. 1 and 2. After the compressed springs 14 are inserted between the plies 24, 26, the longitudinal seam forming station 52 joins the upper and lower plies 24, 26 of the fabric 16 together proximate their respective free edges 28 thereby initially enclosing the springs 14 within the fabric 16. In a presently preferred embodiment, a longitudinal seam 54 is formed between a thermal weld head 56 which reciprocates downwardly and upwardly for cooperating welding engagement and disengagement, respectively, relative to an anvil 58 positioned below the lower ply 26. The reciprocating weld head 56 and anvil 58 cooperate to form the longitudinal seam 54 in the fabric 16 by welding the respective plies 24, 26 together ultrasonically, thermally, or the like as is well known by those skilled in the art. Alternatively, the anvil 58 is moved reciprocally while the thermal weld head 56 remains stationary. The springs 14 remain compressed during the formation of the longitudinal seam 54 and weld with their longitudinal axes 60 generally perpendicular to the longitudinal seam 54. It should be appreciated that other means for joining the plies 24, 26 together to form the seams such as stitching, staples, or other means are well within the scope of the present invention.

A first transport station 62 is located downstream from the longitudinal seam forming station 52 and, in a presently preferred embodiment, includes four transport bands 64. Each band 64 passes over spaced forward and trailing rollers 66, 68, at least one of which is rotationally driven. A first pair of bands 64a at the first transport station 62 contacts the fabric 16 proximate the longitudinal fold line 22 passing therebetween. Another pair 64b of transport bands 64 contacts the fabric 16 proximate the longitudinal seam 54 as shown in FIGS. 1 and 2. As the bands 64 pass around the spaced rollers 66, 68 in contact with the fabric 16, the fabric 16 is pulled from the supply roll 18 through the upstream stations and is advanced toward a downstream spring expansion station 70.

The compressed springs 14 are permitted to relax and expand within the fabric 16 at the spring expansion station 70. In a first embodiment, the expansion of the springs 14 is controlled by a pair of oppositely rotating rotational members 72 on opposite sides of the springs 14 as shown in FIG. 1. An axis of rotation 74 of each of the rotational members 72 according to the first presently preferred embodiment of FIG. 1 is generally parallel to the longitudinal axes 60 of the springs 14. Each rotational member 72 includes a plurality of arcuate-shaped recesses 76, each of which combine with a similarly configured recess 76 in the corresponding rotation member 72 on the opposite side of the spring 14 to partially surround each spring 14 and thereby control the expansion thereof. Additionally, the rotational members 72 assist in advancing the springs 14 and fabric 16 toward a transverse seam forming station 78 located downstream therefrom.

The transverse seam forming station 78 forms a transverse seam 80 in the fabric 16 between each of the adjacent springs 14 which have expanded within the fabric 16 from their compressed configuration. Preferably, the transverse seam forming station 78 includes a transverse seam weld head 82 and a cooperating transverse seam anvil 84 located on opposite sides of the forming string 12 of pocketed coil springs 14 from each other, as shown in FIG. 1. As the springs 14 advance toward and through the transverse seam forming station 78, the fabric 16 between the springs 14 is joined together thereby completing individual pockets 86 for each of the springs 14 and enclosing the springs 14 within the fabric 16. Once again, it should be readily appreciated that other means for forming the transverse seam 80 such as stitching, staples or the like may be used within the scope of this invention. While the transverse seam 80 is formed, the fabric 16 is needed or gathered. As such, the string 12 of pocketed coil springs 14 must give in or contract somewhat to accommodate the seam forming process. This can be accomplished with an active mechanism such as a driven transport system or with in a passive manner such as friction between the fabric 16 and the transport rotational members 72.

The longitudinal axes 60 of the springs 14 remain generally parallel to the transverse seams 80 in the fabric 16. However, due to the expansion of the springs 14, the longitudinal seam 54 formed at the free edges 28 of the fabric 16 is positioned generally on a side face 88 of the string 12 of pocketed coil springs 14 between top and bottom ends 90, 92 of the pocketed coil spring 14 as shown particularly in FIGS. 5 and 6. With the longitudinal axes 60 of the springs 14 generally aligned and parallel with one another within individual fabric pockets 86, the present invention avoids the need for turning the springs 14 within the fabric pockets 86 as is required in many prior art systems.

Referring to FIGS. 5 and 6, the longitudinal seam 54 preferably becomes attached to the pockets 86 when the transverse seam 80 is formed by the transverse seam forming station 78. As such, in the region of the fabric 16 proximate the transverse seam 80, four layers of fabric 16 are welded together at the transverse seam forming station 78. It should be appreciated that there are other methods to fix the seam 80 in this manner, for example, the longitudinal seam 54 could be positioned prior to entering the transverse seam forming station 78 even if it is not welded to the pockets 86 with the transverse seam 80. Further, the longitudinal seam 54 may be located anywhere between the top and bottom of the string although it is shown in the drawings as approximately in the middle thereof.

A downstream or second transport station 94 preferably includes a pair of oppositely rotating transport wheels 96 each with an axis 98 of rotation generally parallel to the longitudinal axes 60 of the springs 14. A plurality of arcuate recesses 100 on the periphery of the transport wheels 96 cooperate to at least partially surround the pocketed springs 14 and advance them from the upstream transverse seam forming station 78 for discharge and subsequent packaging, storage or processing into a mattress, cushion or innerspring unit.

An alternative embodiment of this invention is shown in FIGS. 3 and 4 and components of the system of FIGS. 3 and 4 which are similar to those of the first embodiment shown in FIGS. 1 and 2, are identified by identical reference numerals and the previous detailed description with respect to those items provided hereinabove is likewise applicable to the embodiment of FIGS. 3 and 4. The second presently preferred embodiment shown in FIGS. 3 and 4 includes divergent transport bands 102 located above and below the fabric 16 and enclosed springs 14 at the spring expansion station 70. The transport mechanism could be embodied with wheels as in FIGS. 1 and 2 and/or transport bands as in FIGS. 3 and 4 which are located on the top and bottom of the string or the lateral side surfaces as desired. Each of the transport bands 102 of FIGS. 3 and 4 pass over forward and trailing rollers 104, 106, as shown particularly in FIG. 4. Furthermore, a separation distance between the transport bands 102 increases in a downstream direction thereby permitting the controlled expansion of the springs 14 positioned in the fabric 16 between the transport bands 102. The relaxed and expanded springs 14 are then advanced to the downstream transverse seam forming station 78 so that the transverse seam 80 may be positioned between the adjacent springs 14 to complete the individual fabric pockets 86.

An additional feature of this invention is shown in FIGS. 7 and 8 and is particularly adapted for use in constructing strings 12 of pocketed coil springs 14a having a barrel shaped configuration as shown in FIG. 7. Barrel shaped springs 14a are well known in the industry and include a profile 108 in which the middle turns 110 of the spring 14a have a greater diameter than the top turn 112 and bottom turn 114 of the spring 14a. For example, the top and bottom turns 112, 114 of the barrel shaped spring 14a may have a diameter of about 1.625 inches and the middle turn 110 have a diameter of about 2.5 inches. When barrel shaped springs 14a are used in the string 12, the transverse seam 80a adjacent to the spring 14a conforms to the profile 108 of the spring 14a as shown in FIG. 7. With the transverse seam 80a conforming to the profile 108 of the spring 14a encased in the pocket a tighter pocket is produced with less loose fabric 16 in the string 12 and a better overall product, especially with springs 14a having a non-linear profile. With barrel shaped springs 14a, the transverse seam 80a adjacent thereto has a concave shape and because the transverse seam 80a is located between adjacent barrel shaped springs 14a the seam 80a may have a pair of outwardly facing concave shapes forming an X or similar configuration. A weld head 82a suitable for forming the transverse seam 80a is shown in FIG. 8 in which a number of studs 116 are arranged in the pattern shown so that adjacent studs 116 proximate the top and bottom of the weld head 82a are spaced farther apart than those in the middle to conform with the profiles 108 of the adjacent barrel shaped springs 14a. Although the transverse seam 80a of FIG. 7 is symmetric, other configurations are contemplated within the scope of this invention. Moreover, in another sense, this feature of the invention is useful not only for barrel shaped springs 14a to form a tighter, more conforming fabric pocket, but also for springs having a non-linear profile in general such as the barrel shaped springs and hour glass shaped springs in which the middle turns have a lesser diameter than the top and bottom turns.

From the above disclosure of the general principles of the present invention and the preceding detailed description of at least one preferred embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, we desire to be limited only by the scope of the following claims and equivalents thereof.

Claims

1. A system for forming a string for forming a string of pocketed coil springs, each of the springs being enclosed within a pocket formed of fabric, the system comprising:

a spring insertion station at which compressed springs are individually inserted between first and second plies of the fabric;

a longitudinal seam forming station located downstream from the spring insertion station, the longitudinal seam forming station joining by welding, stitching, or stapling the first and second plies of the fabric together to form a longitudinal seam proximate free edges of the first and second plies;

a spring expansion station located downstream from the longitudinal seam forming station, the spring expansion station permitting the springs to at least partially expand between the first and second plies so that a longitudinal axis of each psring is generally perpendicular to the longitudinal seam;

a transverse seam forming station forming a transverse seam in the fabric to separate each pair of adjacent springs and thereby enclose each of the springs within a fabric pocket when inserted therein; and

a transport station which advances the fabric and springs contained therein through the respective stations;

wherein the transport station further comprises a pair of rotating transport members spaced on opposite sides of the fabric and located downstream from the spring expansion station, each of the pair of the rotating transport members comprises a pluarlity of arcuate shaped recesses, each of the recesses of the rotating transport member on one side of the fabric combine with one of the recesses of the rotating transport member on the opposite side of the fabric to partially surround each spring and the surrounding fabric, each of the rotating transport members making complete revolutions about a fixed axis of rotation to thereby pull the fabric and springs contained therein through the respective stations.

2. A system for forming a string of pocketed coil springs, each of the springs being enclosed within a pocket formed of fabric, the system comprising:

a spring insertion station at which compressed springs are individually inserted between first and second plies of the fabric;

a longitudinal seam forming station located downstream from the spring insertion station, the longitudinal seam forming station joining by welding, stitching, or stapling the first and second plies of the fabric together to form a longitudinal seam proximate free edges of the first and second plies;

a spring expansion station located downstream from the longitudinal seam forming station, the spring expansion station permitting the springs to at least partially expand between the first and second plies so that a longitudinal axis of each spring is generally perpendicular to the longitudinal seam;

a transverse seam forming station a transverse seam in the fabric to separate each pair of adjacent springs and thereby enclose each of the springs within a fabric pocket when inserted therein; and

a transport station which advances the fabric and springs contained therein through the respective stations;

wherein the spring expansion station further comprises a pair of rotating members disposed on opposite sides of the springs within the fabric, and each of the rotating members making complete revolutions about a fixed axis of rotation.

3. A system for forming a string of pocketed coil springs, each of the springs being enclosed within a pocket formed of fabric, the system comprising:

a spring insertion station at which compressed springs are individually inserted between first and second plies of the fabric;

a longitudinal seam forming station located downstream from the spring insertion station, the longitudinal seam forming station joining the first and second plies of the fabric together to form a longitudinal seam proximate free edges of the first and second plies;

a spring expansion station located downstream from the longitudinal seam forming station, the spring expansion station permitting the springs to at least partially expand between the first and second plies so that a longitudinal axis of each spring is generally perpendicular to the longitudinal seam, wherein the spring expansion station further comprises a pair of rotating members on opposite sides of the springs within the fabric, wherein the axes of rotation of the rotating members are generally parallel to the longitudinal axes of the springs and each rotating member comprises a plurality of arcuate shaped recesses which combine to partially surround each spring;

a transverse seam forming station forming a transverse seam in the fabric to separate each pair of adjacent springs and thereby enclose each of the springs within a fabric pocket when inserted therein; and

a transport station which advances the fabric and springs contained therein through the respective stations.

4. A system for forming a string of pocketed coil springs, each of the springs being enclosed within a pocket formed of fabric, the system comprising:

a spring insertion station at which compressed springs are individually inserted between first and second plies of the fabric;

a longitudinal seam forming station located downstream from the spring insertion station, the longitudinal seam forming station joining the first and second plies of the fabric together to form a longitudinal seam proximate free edges of the first and second plies;

a spring expansion station located downstream from the longitudinal seam forming station, the spring expansion station permitting the springs to at least partially expand between the first and second plies so that a longitudinal axis of each spring is generally perpendicular to the longitudinal seam, wherein the spring expansion station further comprises a pair of rotating members on opposite sides of the springs within the fabric, wherein the axes of rotation of the rotating members are generally perpendicular to the longitudinal axes of the springs and each rotating member comprises a band passing over spaced rotational mounted rollers, wherein a separation distance between the bands increases in a downstream direction to thereby control the expansion of the springs between the bands;

a transverse seam forming station forming a transverse seam in the fabric to separate each pair of adjacent springs and thereby enclose each of the springs within a fabric pocket when inserted therein; and

transport station which advances the fabric and springs contained therein through the respective stations.

5. A system for forming a string of pocketed coil springs, each of the springs being enclosed within a pocket formed of fabric, the system comprising:

a spring insertion station at which compressed springs are individually inserted between first and second plies of the fabric;

a longitudinal seam forming station located downstream from the spring insertion station, the longitudinal seam forming station joining the first and second plies of the fabric together to form a longitudinal seam proximate free edges of the first and second plies;

a spring expansion station located downstream from the longitudinal seam forming station, the spring expansion station permitting the springs to at least partially expand between the first and second plies so that a longitudinal axis of each spring is generally perpendicular to the longitudinal seam;

a transverse seam forming station forming a transverse seam in the fabric to separate each pair of adjacent springs and thereby enclose each of the springs within a fabric pocket when inserted therein; and

a transport station which advances the fabric and springs contained therein through the respective stations;

wherein the longitudinal seam forming station and the transverse seam forming station each further comprise a cooperating thermal weld head and anvil to form thermal welds in the fabric;

wherein the weld head and the anvil at the transverse seam forming station are configured to produce a non-linear transverse seam which conforms to a non- linear profile of the adjacent spring.

6. A system for forming a string of pocketed coil springs, each of the springs being enclosed within a pocket formed of fabric, the system comprising:

a spring insertion station at which compressed springs are individually inserted between first and second plies of the fabric;

a longitudinal seam forming station located downstream from the spring insertion station, the longitudinal seam forming station joining by welding, stitching, or stapling the first and second plies of the fabric together to form a longitudinal seam proximate free edges of the first and second plies;

a spring expansion station located downstream from the longitudinal seam forming station, the spring expansion station permitting the springs to at least partially expand between the first and second plies so that a longitudinal axis of each spring is generally perpendicular to the longitudinal seam;

wherein the spring expansion station further comprises a pair of rotating members disposed on opposite sides of the springs within the fabric, wherein the axes of rotation of the rotating members are generally perpendicular to the longitudinal axes of the springs

a transverse seam forming station forming a transverse seam in the fabric to separate each pair of adjacent springs and thereby enclose each of the springs within a fabric pocket when inserted therein; and

a transport station which advances the fabric and springs contained therein through the respective stations;

wherein the orientation of the longitudinal axes of the springs remains generally unaltered from the spring insertion station through formation of the string of pocketed coil springs.

7. A system for forming a string of pocketed coil springs, each of the springs being enclosed within a pocket formed of fabric, the system comprising:

a spring insertion station at which compressed springs are individually inserted between first and second plies of the fabric;

a longitudinal seam forming station located downstream from the spring insertion station, the longitudinal seam forming station joining the first and second plies of the fabric together to form a longitudinal seam proximate free edges of the first and second plies;

a spring expansion station located downstream from the longitudinal seam forming station, the spring expansion station permitting the springs to at least partially expand between the first and second plies so that a longitudinal axis of each spring is generally perpendicular to the longitudinal seam;

a transverse seam forming station forming a transverse seam in the fabric to separate each pair of adjacent springs and thereby enclose each of the springs within a fabric pocket when inserted therein, wherein the transverse seam forming station forms a non-linear transverse seam which conforms to a non-linear profile of the adjacent spring; and

a transport station which advances the fabric and springs contained therein through the respective stations.

8. A system for forming a string of pocketed coil springs, each of the springs being enclosed within a pocket formed of fabric, the system comprising:

a spring insertion station at which compressed springs are individually inserted between first and second plies of the fabric;

longitudinal seam forming station located downstream from the spring insertion station, the longitudinal seam forming station including a cooperating thermal weld head and anvil to thermally weld the first and second plies of the fabric together to form a longitudinal seam proximate free edges of the first and second plies;

a spring expansion station located downstream from the longitudinal seam forming station, the spring expansion station including a pair of rotating members on opposite sides of the springs within the fabric to permit the springs to at least partially expand between the first and second plies so that a longitudinal axis of each spring is generally perpendicular to the longitudinal seam;

a transverse seam forming station including a cooperating theremal weld head and anvil to thermally weld a transverse seam in the fabric between each pair of adjacent springs to thereby enclose each of the springs within a fabric pocket when inserted therein; and

a transport station which advances the fabric and springs contained therein through the respective stations, the transport station including a pair of rotating transport members spaced on opposite sides of the fabric and located downstream from the spring expansion station.

9. A system for forming a string of pocketed coil springs, each of the springs being enclosed within a pocket formed of fabric, the system comprising:

a spring insertion at which compressed springs are individually inserted between first and second plies of the fabric;

longitudinal seam forming station located downstream from the spring insertion station, the longitudinal seam forming station including a cooperating thermal weld head and anvil to thermally weld the first and second plies of the fabric together to form a longitudinal seam proximate free edges of the first and second plies;

a spring expansion station located downstream from the longitudinal seam forming station, the spring expansion station including a pair of rotating members on opposite sides of the springs within the fabric to permit the springs to at least partially expand between the first and second plies so that a longitudinal axis of each spring is generally perpendicular to the longitudinal seam;

a transverse seam forming station including a cooperating thermal weld head and anvil to thermally weld a transverse seam in the fabric between each pair of adjacent springs to thereby enclose each of the springs within a fabric pocket when inserted therein, wherein the weld head and anvil of the transverse seam forming station are configured to produced a non-linear transverse seam which conforms to a non-linear profile of the adjacent spring; and

a transport station which advances the fabric and springs contained therein through the respective stations, the transport station including a pair of rotating transport members spaced on opposite sides of the fabric and located downstream from the spring expansion station.

10. A system for forming a string of pocketed coil springs, each of the springs being enclosed within a pocket formed of fabric, the system comprising:

a spring insertion station at which compressed springs are individually inserted between first and second plies of the fabric, each of the springs having non-linear profile between a top and a bottom thereof;

a longitudinal seam forming station located downstream from the spring insertion station, the longitudinal seam forming station joining the first and second plies of the fabric together to form a longitudinal seam proximate free edges of the first and second plies;

a spring expansion station permitting the springs to at least partially expand between the first and second plies;

a transverse seam forming station forming a transverse seam in the fabric to separate each pair of adjacent springs and thereby enclose each of the springs within a fabric pocket when inserted therein, the transverse seam having a non-linear profile conforming to that of the adjacent spring; and

a transport station which advances the fabric and springs contained therein through the respective stations.